Construction of rugs of pile fabrics



May 14, 1935. I c H. DAWSON 2,001,527

CONSTRUCTION OF RUGS OF FILE FABRICS Filed Jan. 11, 1955 7051: F1651. 2 PAIOK ART wmvrae:

CHARLES HEEBEET DAV/SON,

Patented May '14, 1935 PATENT OFFICE CONSTRUCTION OF RUGS OF PILE FABRICS Charles Herbert Davison, Edgerstoune, Princeton, N. J

Application January 11, 1935, Serial No. 1,313

5 Claims.

My invention provides a method of and means for binding cut edges of pile fabric to prevent raveling of the pile tufts and other elements of the fabric at such cut edges. Although my invention may be employed with particular advantage in connection with Axminster rugs and carpets, it is not limited to such embodiments but is applicable to pile fabrics of any kind.

It is the present trade practiceto charge $1.27

per yard for binding the cut edge of an Axminster fabric by a method and means which are standard practice in the trade and which consist in allowing one and one-half inches extra length of the fabric at any edge which is to be bound, plucking the pile tufts from that inch and a half length and the full width of the fabric, binding the cut edge by the use of a sewing machine which overcasts the cut edge to an extent of about one-half inch with a coarse thread in stitches resembling those used for forming buttonholes. Then bending the plucked portion of the fabric backing backward upon and parallel with the face of the fabric opposite to the tufts, and hemming it to the body of the fabric by a line of machine stitches intermediate of the width of the overcasting. Obviously such a method of procedure is wasteful of the pile material of the fabric and laborious and consequently costly. Moreover, the edge of a fabric thus finished does not lie fiat upon a plane surface but is upheld' by the thick portion thereof turned under and, consequently, such raised edge of the fabric is subjected to greater wear than the body of the fabric and becomes threadbare.

Therefore, it is .the object and effect of my invention to not only minimize the waste, labor and cost of binding a cut edge of a pile fabric but also to permit the cut edge, when bound, to lie fiat upon a plane surface and thus avoid the extraordinary wear incident to the ordinary construction aforesaid.

As hereinafter described, it is characteristic of my invention that no portion of the fabric, either of the pile or backing, is wasted, in forming a plurality of rugs from a web of fabric originally Woven as a single piece. The backing of said web is first coated with elastic cement in strips extending upon the opposite side of each line where the fabric is to be severed to form successive rugs. Said strips of cement are then dried and the fabric severed intermediate of each strip to form cut edges of adjoining rugs without ravcling of either the pile or backing. Each cut edge is thereafter overcast to the extent of about onehalf inch with a coarse thread, such thread en- .thus secured to the back of the fabric by the cement, with one edge of said band flush with the cut edge of the fabric so that the fabric thus bound will lie flat upon a plane surface.

My invention includes the various novel features of construction, arrangement, and method of procedure hereinafter more definitely specified.

In said drawing-Fig. I is an elevation of a portion'of the longitudinal edge of an Axminster pile fabric illustrating the prior art method and means for binding the cut edge thereof above described.

Fig. II is an elevation of a portion of the longitudin'al edge of an Axminster pile fabric having a cut edge thereof which is at the right in said figure, bound in accordance with my invention.

Fig. III is a perspective view of a pile fabric as it comes from the loom, with dash lines indicating where it is severed transversely at intervals throughout its length, to form rugs without Waste of any portion of the fabric and to be bound in accordance with this invention.

Fig. IV is a perspective view of the near corner and cut edge of the central panelin Fig. III, illustrating the means and method for binding such cut edge in accordance with my invention.

Referring to Fig. I which exemplifies the prior art above described, the backing I of the fabric has the pile tufts 2 looped therein and primarily extending to the cut edge 3. However, the tufts 2 are plucked from the backing to the extent from edge 3 to the region 6, Thereupon, the cut edge 3 is overcast with stitches 5 and the plucked portion of the fabric bent backward thereon beneath the fabric and secured by the line of machine stitches 6 extending through said cut'edge 3 intermediate of the longitudinal extent of' the threads 5 and through the body of the fabric I. As indicated, the body of the fabric at theedge thus bound'is uplifted from the plane surface I so as to be subjected to greater wear than the other portions of the fabric.

Referring to Fig. II which shows my improve ment, the backing l of the fabric has the pile tufts 2lo'oped therein to the cut edge 8 thereof, and the backing wefts at an adjoining said edge 8 are overcast to the extent of about one-half inch in Fig. II is such that the fabric thus boundlwilllie substantially fiat upon a plane surface, as

distinguished from that'of the prior art shown in Fig. I. i

My invention may be employed to form a plurality of rugs from a web I 2 of pile fabric by.

determining where the web is to be severed, as

indicated by dash lines I 9 in Fig. III, and then applying a coating of elastic cement-in a strip ll extending upon opposite sides of each line l9; drying said cement strips; and thereafter severing the fabric at each line I3 intermediate of the width of said strips ii. That operation insures forming opposite cut edges at each line 19 without waste of any of the material of the fabric to form from said primarily continuousweb H a succession of rugs l5, l6, l1, etc.

Referring to Fig. IV, which shows the near corner of the rug panel Hi; the backing wefts, say

flve, at and adjoining the cut edge 9 thereof,

which have been connected by the elastic cement half of a strip ll are then overcast with stitches of thread 9 extending at, the roots of 'the pile tufts and encircling said wefts, as indicated in Fig. II, so as to bind the edge of the fabric and prevent raveling thereof and afford a. substantial reinforcement of said out edge. The fabric backing I is then coated with elastic cement, as indicated at l9, overlying said over-- cast stitches 9 and extending over an adjoining strip of the fabric backing to the extent of about one inch from the cut edge 9. That coating l9 may advantageously overlie the cut edge 8 to.

cement the overcast threads 9 to said edge. The

' fiat band'of tough material It is then secured parallel with the plane of the fabric by said adhesive its and with one edge of said band i9 flush with the cut edge of the fabric 9, asshown in Figs. II and IV, by pressing said band flat upon the cement [9, as at the near corner of Fig. IV.

Although any suitable adhesive may be employed in the manner above specified, I have found it"convenient to employ a'mixture of approximately three parts of what is known. tothe trade as filler paste to wit, a pasteiormed of flour of grain such as rye boiled in water, mixed with approximately one part'of rubber cement, i. e., liquid para gum of the consistency of commercial liquid glue; the mixture forming thepreferable elastic adhesive aforesaid, being of that consistency when applied, but capable of setting as quickly as animal glue or grain paste.

It may be observed that the present invention is distinguished from that claimed ,in my copending ial .No. 741,978 filed August 29, 1934,"for Letters Patent of the United States for application Improvement in construction of rugs of pile fabrics in that the latter invention necessitates either the waste of tuft material which is plucked from the cutedges of a, primarily continuous web of fabric or the of such-web'of fabric a pattern of tufted regions separated by narrow regions devoid of tufts and, consequently, my present invention is advantageous in that the manufacture of rugs in accordance therewith may be more economically effected than in the manner contemplated in said prior application. A

However, it is to be understood that I do not desire .tolimit myself to the precise details of construction, arrangement or method of procedure above set forth. as it is obvious that various modifications may be made therein without departing from the essential features of my invention, as instance, the edge 9 may be out before it is cemented, and the underside of band l9 may be coated with adhesive 20. before it is applied to the fabric. Y

Iclaim: I 7 1 1. The method of finishing the cut edge of a defined in the appended claims. For r pile fabric which. includes severing the entire fabric, both backing and pile tufts, without loss ing; and covering said cement with a flat band i of tough material secured parallel with the plane Y of the fabric by said adhesive and with one edge of said band flush with the cut edge of the fabric. 2. A method as in claim 1, including the step of coating with elastic cement the margin of the back ofthe fabric adjoining said out edge which is to be overcast. and drying that coating before overcasting said edge to prevent raveling of the fabric at the cut edge during the over-casting oper- 2. ion. 1

3.. The method of forming a plurality of rugs from a web of pile fabric which consists in applying a coating of elastic cement ina strip extending upon opposite sides of each. line where the fabric is to be severed; drying said cement severing the fabric intermediate of the width of each such strip and thereby forming opposite cut edges without waste of the material of the fabric; over-.

casting the backing wefts at and immediately adjoining each of said out edges, separatelf, with stitches of thread extending over the backing at.

the roots of the pile tufts, and encircling said wefts at the back and cut edge of the fabric so as to bind the edge of thefabric and prevent raveling thereof; coating the back of the fabric with elastic cement overlying said overcast stitches and an adjoining strip of the fabric back-1 ing; and covering said cement with a flat band of tough material'secured parallel with the plane of the fabric by said adhesive and'withone edge of said band flush with\the cut'edge of the fabric.

4. A method as in claim 1. wherein the band is 

